Regrind polyurethane with glycol or polyol additive

ABSTRACT

A surface element including a recycled polyurethane and a glycol or polyol additive is provided. The surface element has an increased tearability as compared to the recycled polyurethane. An article of footwear and methods of preparing an article of footwear are also provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 13/257,343 filed May 9, 2013, which is a 371 ofPCT/CN2010/001479, filed Sep. 25, 2010, which are hereby incorporatedherein by reference, each in its entirety.

FIELD

The present disclosure relates to methods of recycling polyurethane, andmore particularly to methods of incorporating regrind thermoplasticpolyurethane into a surface element.

BACKGROUND

This section provides background information related to the presentdisclosure which is not necessarily prior art.

A significant problem in the production and use of polyurethane resinsis the disposal of thermally degraded and/or off-grade, polyurethaneresins. For example, when a thermoplastic polyurethane (TPU) material isincorporated into various products or used to form products, wastematerial is generated. The waste material includes fully or partiallythermally degraded resins, misformulated resins, or scrap resins. Muchof the waste material with polyurethane in sheet form is the scrap edgesfrom polyurethane materials that have been shaped using a mold. Althoughmany efforts have been made to shape molds to minimize waste, the natureof using sheets of TPU necessarily generates scrap edges.

In prior systems, the waste material was discarded because it was notsuitable for use in the original product. In still other systems, thescrap resin or misformulated resins was separated into small pieces, toform regrind, and the regrind was blended with virgin resin and used inthe same application. Regretfully, only a limited amount of regrind canbe used without sacrificing the desired properties of the particularpolyurethane resin for the application.

Using regrind to provide different parts of an item or for use in a newitem would reduce the need to create virgin thermoplastic polyurethane.Modifications to regrind use would provide alternatives to allow thescrap polyurethane from one component of a product to be used in adifferent component of the product or in a different product. Suchmodifications are environmentally friendly, beneficial in a productionline, increase cost-effectiveness, minimize downtime and loss of plantresources, and minimize the need to produce and purchase virginmaterials.

SUMMARY

This section provides a general summary of the disclosure, and is notcomprehensive of its full scope or all of the disclosed features.

In various aspects, the present teachings provide a surface elementincluding a recycled polyurethane and a glycol or polyol additive. Thesurface element has an increased tearability as compared to the recycledpolyurethane.

In other aspects, the present teachings provide an article of footwearincluding: an upper, a midsole, an outsole, and a surface element. Thesurface element includes a recycled polyurethane and a glycol or polyoladditive. The surface element has a melt index that is at least aboutthree-fold greater than the melt index of the recycled polyurethane.

In still further aspects, the present teachings provide methods ofpreparing footwear having a surface element. A scrap polyurethane iscollected from a shoe component. The scrap polyurethane has a first meltindex and a first tearability. The scrap polyurethane is mixed with aglycol or polyol additive. The first melt index of the scrappolyurethane is increased. A sheet is formed of the polyurethane andglycol or polyol additive mixture. The sheet is applied to an outerregion of an article of footwear. A perimeter of the sheet is torn toform the surface element.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations, and are notintended to limit the scope of the present disclosure.

FIG. 1 depicts an article of footwear according to various aspects ofthe present teachings;

FIG. 2 depicts a surface element being applied to an article of footwearaccording to various aspects of the present teachings; and

FIG. 3 depicts a sheet of material having a surface element according tovarious aspects of the present teachings.

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

Example embodiments are provided so that this disclosure will bethorough, and will fully convey the scope to those who are skilled inthe art. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The method steps, processes, and operations described hereinare not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

In various embodiments, the illustrations of the present teachingsrelate to an article of footwear 10 as shown in FIG. 1. Generally, thearticle of footwear 10 includes an upper 12 and a sole assembly 14. Thesole assembly 14 is attached to the upper 12 and can include an outsole16 and a midsole 18. Optionally, the midsole 18 can include a bladder20. The article of footwear 10 is depicted with an exemplary surfaceelement 22.

While the illustrations and figures relate to an article of footwear, itis understood that the materials and methods detailed are alsoapplicable to apparel such as shirts, patents, hats, gloves, and thelike and also to sports equipment including balls, bats, masks,racquets, backboards, nets, and the like, as non-limiting examples.

Referring to FIGS. 1-3, examples of the surface element 22 are shown.The surface element 22 is also known as surface indicia, features,embellishments, or decorations, as non-limiting examples. The surfaceelement 22 is made of a recycled polyurethane and a glycol or polyoladditive. The surface element 22 has an increased tearability (ordecreased tear resistance) as compared to the unmodified recycledpolyurethane. “Tear resistance” and conversely, “tearability” as usedherein can be defined and measured as set forth in ASTM D1004,incorporated by reference in its entirety. The increased tearabilityallows the surface element 22 to be shaped, torn, or cut withoutexerting a high force. For example, the increased susceptibility totearing allows the surface element 22 to be torn by hand or easilyremoved by a machine without necessarily requiring a sharp die cuttingtool or elaborate machinery. The increased tearability is selected toallow shaping and application of the surface element 22 withoutcompromising its desired strength or durability.

The surface element 22 is any of a text, design, logo, mascot, or theme,as non-limiting examples. In various embodiments, the surface element 22is made of a single color, finish, or pattern, or various combinationsthereof. As shown in FIG. 1, the surface element 22 is an image of thesun while the example in FIG. 3 is text.

The source polyurethane is a scrap or spare material. The sourcepolyurethane includes either a virgin material or material that has beenrecycled at least one time. As a non-limiting example, the sourcematerial traditionally would have been discarded because of a lack ofapparent or easy re-use without cumbersome steps or significant costs.The present teachings help to eliminate this waste and provide anenvironmentally friendly alternative and cost-efficient use for thescrap or spare material.

In various embodiments, the polyurethane is sourced from the samematerial as the subject item (for example, from a component of anarticle of footwear), or the polyurethane is sourced from a differentmaterial wholly separate from the subject item, such as with across-industrial use (for example, a scrap material from an automotivecomponent being recycled and incorporated into a home furnishingelement). In various embodiments, the scrap or recycled polyurethaneprovides all of the source polyurethane in the system. In otherembodiments, the polyurethane can be a mix of virgin and recycledmaterials. Such examples could include from about 5% to about 99% byweight or from about 55% to about 99% by weight of the recycledmaterials with the remainder of the urethane being a virgin material.

In various embodiments, the source polyurethane is a thermoplasticpolyurethane. The thermoplastic urethane is either an ester- orether-based urethane. Others polyurethanes include those selected fromthe group consisting of polyester, polyether, polycaprolactone,polyoxypropylene, and polycarbonate macroglycol based materials, andmixtures thereof. In various embodiments, the recycled polyurethane isformed of any polyurethane or a methylene diphenyl diisocyanate (MDI) ordiisocyanate (DI) derivative. Among the useful isocyanates anddiisocyanates in the source polyurethane include, but are not limitedto, isophorone diisocyanate (IPDI), methylene bis 4-cyclohexylisocyanate (H12MDI), cyclohexyl diisocyanate (CHDI), hexamethylenediisocyanate (HDI), m-tetramethyl xylene diisocyanate (m-TMXDI),p-tetramethyl xylene diisocyanate (p-TMXDI), and xylylene diisocyanate(XDI).

The source polyurethane is optionally cut or ground to form smallerparticles for processing. Such materials are commonly known as regrind.The size of the regrind is selected for convenience, to achieveappropriate melting properties when the regrind is processing, or inlight of the reaction parameters. In various embodiments, the sourcepolyurethane is a combination of polyurethanes having different Shorehardnesses. For example, a mix of two polyurethanes having a Shorehardness of 65 A and a Shore hardness of 85 A, respectively, is employedin various embodiments. A mixture of polyurethanes having differentShore hardnesses further modulates the melt index of the surface element22.

The recycled or regrind polyurethane has a starting melt index andtearability. Generally, the source polyurethane has a high melt index ofup to 20, which would be lower than the melt index of the surfaceelement 22 formed therefrom. The Examples provided later herein furtherillustrate the increase in melt index and tearability according to thepresent teachings.

In various embodiments, the glycol additive that is combined with theregrind or recycled polyurethane is selected from 1,4-butanediol,1,3-butanediol, dipropylene glycol, 1,4-cyclohexane dimethanol, ortripropylene glycol. Similarly, any other difunctional alcohol or chainextenders, and combinations thereof, are able to be employed in thepresent teachings. Particular examples of such materials include,without limitation, ethylene glycol, diethylene glycol, and higherpolyethylene glycol analogs like triethylene glycol; propylene glycol,and higher polypropylene glycol analogs like tripropylene glycol andtetrapropylene glycol; 1,3-propanediol, 1,6-hexanediol, 1,7-heptanediol,neopentyl glycol, dihydroxyalkylated aromatic compounds such as4,4′-isopropylidene diphenol, (bisphenol A), resorcinol, catechol,hydroquinone, benzenedimethanols, the bis(2-hydroxyethyl)ethers ofhydroquinone and resorcinol; p-xylene-α,α′-diol; thebis(2-hydroxyethyl)ether of p-xylene-α,α′-diol; m-xylene-α,α′-diol andthe bis(2-hydroxyethyl) and alkylene oxide adducts of such diols. Othercandidates include glycerin, trimethylolpropane, neopentyl glycol, andthe like. Further, low molecular weight polyols formed by the reactionof a glycolic extender and a diacid such that the resulting polymer hasa molecular weight below about 500 are also suitable. A single glycol orpolyol additive or a plurality of different glycol additives and/orpolyol additives is combined with the regrind polyurethane in thepresent teachings.

The glycol or polyol additive is added in a limited amount to theregrind polyurethane. Generally, the glycol or polyol additive isprovided in an amount of less than about 10% by weight. In furtherembodiments, the glycol or polyol additive is added in an amount ofabout less than 5% by weight down to an amount of less than about 1% byweight. In preferred embodiments, the glycol or polyol is a liquid atroom temperature to facilitate metering, however, low melting solids(120 degrees C. or less) are also successfully employed in the presentteachings. In embodiments where the glycol or polyol has a relativelyhigh boiling point, such as with tripropylene glycol and 1,4cyclohexanedimethanol, fuming during processing and the formation ofdeposits on metal rolls during extrusion are reduced.

The amount of glycol or polyol added will provide the appropriateincrease in flow rate and melt index for the particular combination ofthe glycol or polyol additive and the regrind polyurethane. In variousembodiments, the amount of the glycol or polyol additive added issufficient to provide a melt index of from about 50 to about 300, or amelt index that is several fold higher than the source polyurethane. Itis believed that the melt index increases due to the glycol or polyoladditive serving as a chain extender. This decreases the molecularweight of the resultant urethane which in turn increases flow andtearability.

An example method of measuring the melt index is provided in ASTM D1238,incorporated by reference in its entirety. Further, the addition of theglycol or polyol additive to the regrind polyurethane will decrease themolecular weight of the modified polymer as compared to the molecularweight of the starting recycled polyurethane.

Optionally, additional additives can be employed including, but notlimited to, pigments, various stabilizers, flame retardants, wax,antioxidants, etc. For example, if added various plasticizers wouldincrease the flexibility and durability of the final product as well asfacilitate the processing of the material from a resinous form to amembrane or sheet useful for a surface element. Fillers are alsooptionally included, such as fibrous and particulate materials,non-polar polymeric materials and inorganic anti-block agents. Stillother additives or processing aids are optionally included such as moldrelease agents and lubricants, as are known in the art. Any of theseadditives are either provided with the source polyurethane or are addedat a different processing step. It is understood that the additives willnot significantly alter the desired melt index and ease of tearing forthe surface element 22. It is understood that combinations of theadditives allow for customization of color and texture, for example, ofthe surface element 22.

As illustrated in the Examples, the surface element 22 may have a meltindex that is at least about three-fold greater than the melt index ofthe source regrind polyurethane. In various embodiments, the surfaceelement 22 has a melt index of at least 100 grams/10 minutes at 190degrees C./8700 sec. The higher melt index as compared to that of thesource polyurethane indicates a better propensity to flow andfacilitates more easily applying the surface element 22 to theunderlying substrate.

According to various embodiments of the present teachings, methods ofpreparing a surface element 22 for an article of footwear 10 areprovided. To prepare the surface element 22, source polyurethane, forexample, at least partly from scraps of a shoe component (bladder, sole,upper, etc.) is used.

As detailed above, the source material is a polyurethane regrind thathas a starting Shore A hardness and a melt index. If desired, thehardness of the source polyurethane can be reduced by blending it with asofter polyurethane. Also, if desired, a small amount of a virginpolyurethane (10% or less by weight) is added.

The glycol or polyol is then added in the desired amount, preferablyless than about 10% by weight. In some embodiments, the polyurethanestream and glycol or polyol are processed on a twin screw extruder byadding the latter via a metering pump. The polyurethane stream is addedvia a loss in weight feeder that allows a constant ratio between the twomaterials to be maintained. In other embodiments, the glycol or polyolis added to the feed throat, to a downstream port, or into the melt viaan injector, for example. The extruder output is optionally eitherstrand pelletized or pelletized via an underwater pelletizer or othermethods well known to the art. In such embodiments, the melting andmixing of the two ingredients is controlled by process conditions andthe twin screw extruder feed is less affected by the lubricating effectof the glycol or polyol addition. Additives such as those listed aboveare optionally added during the compounding process.

In still other embodiments, the glycol or polyol is added to the polymeras a master batch that can be made in a non-fluxing batch mixer byspraying the glycol or polyol from a number of nozzles that are fed by ametering pump. The source polyurethane absorbs up to about 5% of glycolor polyol and forms a free flowing mix. The absorption process is spedup by warming the mix to a suitable temperature, for example to about 80degrees C. Regrind is particularly suited for such processes because theirregular shape of regrind particles speeds up the absorption of theglycol or polyol. The regrind that has absorbed the glycol or polyol isrun through an extruder if it contains the correct amount of glycol orpolyol, or it can be treated as a master batch and be blended withsource polyurethane that does not contain glycol or polyol, forinstance. This minimizes heat addition and slippage of the polyurethaneduring the single screw extrusion.

Yet another addition method is to simply pump the glycol or polyol froma metering pump into the feed throat of the extruder using an injectionport in the barrel or an injection port on the screw. The ratio ofglycol or polyol to polyurethane is controlled, such as by using ametering pump and screw speed as known in the art.

With reference to FIGS. 2 and 3, regardless of the technique selected,in various embodiments, the materials provide a sheet 100 or anothersuitable shape. The sheet 100 or a region of the sheet is applied to anouter region of the article of footwear 10. The footwear 10 can beassembled when the surface element 22 is applied, as illustrated, or thesurface element can be applied to a distinct component of the article offootwear 10 prior to assembly thereof. In various embodiments, the sheet100 is either pre-formed in a particular shape such that no extrasurface element material is used, or the sheet is a universal shape. Thesurface element 22 is applied to the region of the article of footwear10 and the perimeter 102 of the sheet outside of the weld lines aboutthe desired shape (or surface element 22) is removed. In suchembodiments, the perimeter 102 of the sheet 100 is removed to form thesurface element 22. The melt index allows the perimeter 102 to be rippedcleanly away around the weld without disturbing the surface elementfixed to the article of footwear 10. Any scrap material from the sheet100 can be recycled or reused to form other areas of a surface element22. In various embodiments, the sheet 100 optionally includesperforations (not shown) to facilitate easy removal of the surfaceelement 22.

The surface element 22 is fixed to the article of footwear 10.Application methods include RF welding, heat transfer, laminating, andthe like. The surface element 22 is able to be applied to any of theupper 12, midsole 18, or outsole 16 of the article of footwear 10. Thearticle of footwear 10 includes any type of shoe, boot, or sandal. Invarious embodiments, the article of footwear 10 is an athletic shoe.

In various embodiments, the sheet 100 includes a plurality of surfaceelements 22. In such embodiments, the surface elements 22 can be placedalong different areas of an article of footwear 10 or on differentarticles of footwear 10. Providing the sheet 100 with the plurality ofsurface elements 22 makes the system more cost-effective and furtherminimizes generation of scrap materials.

As detailed above, the surface element 22 can also be applied to appareland/or sports equipment. In such embodiments, the application methodscan be modified to include stitching, in addition to the aboveapplication methods. The application conditions, such as temperature andamount of pressure exerted, are modified for the respective substrate.

The following Examples provide illustrations of the present teachings.

EXAMPLES

A thermoplastic polyurethane (TPU) sheet was produced that wasapproximately 3 feet wide, having different gauges, and showing eithersmooth/fine matte or matte/fine matte finishes. The feed was anester-based thermoplastic polyurethane regrind derived from methylenediphenyl diisocyanate (MDI) that had a Shore hardness of 90 A and a meltindex of 9.4 grams/10 minutes at 190 degrees C./8700 grams. Also, 4% ofa TPU concentrate that contained a UV stabilizer and a small amount of ablue tint were included in the mixture. The sheet was processed on a 3.5inch extruder equipped with a 3-roll stand. 1,4-butanediol (BDO) wasadded via a metering pump to the extruder feed throat. The amount of BDOadded was a few tenths of a percent. As shown in Table 1, the finalsheet tested and labeled Samples 1-10 had melt indexes of from about 30to 60 grams/10 minutes at 190 degrees C./8700 grams. The melt index ofthe control sheet extruded from a similar regrind without the BDO wasonly 16 grams/10 minutes at 190 degrees C./8700 grams, also shown inTable 1.

TABLE 1 Melt Index Modulus at: Sample Thickness (190 C./ TS Percent 50%100% 200% 300% Die C Number Finish mm 8700) Direction psi Elongation psipsi psi psi (pli) 1 matte/ 0.3 51 machine 12160 541 1123 1314 1862 3629782 fine direction matte transverse 11976 598 1051 1207 1586 2719 807direction 2 matte/ 0.5 31 machine 9912 551 1055 1228 1660 2947 717 finedirection matte transverse 10161 561 858 986 1356 2597 726 direction 3matte/ 0.7 59 machine 8948 564 977 1135 1449 2319 680 fine directionmatte transverse 8702 530 924 1951 1401 2592 704 direction 4 matte/ 0.842 machine 8744 526 1038 1171 1588 2871 676 fine direction mattetransverse 8058 567 951 1063 1405 2394 687 direction 5 matte/ 1 40machine 10638 578 1090 1239 1657 2730 660 fine direction mattetransverse 10302 572 1104 1235 1645 2821 674 direction 6 smooth/ 0.3 51machine 12284 594 1181 1384 1869 3103 770 fine direction mattetransverse 10022 612 1015 1176 1571 2837 773 direction 7 smooth/ 0.5 40machine 9934 487 1087 1331 2027 3874 725 fine direction matte transverse9669 592 944 1079 1360 2285 790 direction 8 smooth/ 0.7 31 machine 8758542 906 1063 1456 2469 642 fine direction matte transverse 8661 563 10331157 1482 2513 649 direction 9 smooth/ 0.8 44 machine 9375 586 984 11401458 2293 678 fine direction matte transverse 8961 572 955 1078 13672222 674 direction 10 smooth/ 1 42 machine 8391 607 866 982 1274 2111665 fine direction matte transverse 7875 573 869 975 1254 1997 645direction control matte/ 1 16 machine 8336 520 1076 1290 1799 3108 687sheet matte direction without BDO transverse 8407 519 1030 1194 16102846 693 direction

As shown in Table 2, Samples 11-18 contained either 2% or 5% BDO in aTPU regrind with a melt index ranging for 8 to 20 grams/10 minutes at190 degrees C./8700 grams. Samples 11-18 were prepared according toTable 2 by mixing the respective BDO and TPU regrind in a non-fluxingmixer run at 80 degrees C. Different amounts of the samples werecombined with regrind that was free of 1,4-butanediol and then extrudedinto sheet. The TPU regrind was ester-based and had a melt index of 20grams/10 minutes at 190 degrees C./8700 grams. As shown in Table 3, themelt index of Samples 11-18 increased multiple-fold with increasingamounts of 1,4-butanediol.

TABLE 2 Melt Index in Percent grams/10 Sample Percent of 2% Percent of5% of BDO minutes 190 C. Number BDO Additive BDO Additive in feed 8700grams 11  5 — 0.1 54 12   7.5 — 0.15 40 13 —  2 0.1 54 14 —  3 0.15 6815 25 — 0.5 64 16 — 10 0.5 80 17 — 16 0.8 140 18 — 20 1 110 control nonenone 0 30

As shown in Table 3, the melt index of Samples 11-18 increased withincreasing amounts of 1,4-butanediol. Notably, Sample 18 contained 1%BDO in the feed and had a Die C tear strength of only 564 pounds/inch.Sample 15, for example, contained 0.5% BDO in the feed and had a Die Ctear strength of 693.5 pounds/inch. To the contrary, the control withoutany BDO had a Die C tear Strength of 722.5 pounds/inch. Thisdemonstrates that the increase in BDO concentration decreases the tearstrength (or conversely increases the ease of tearing).

TABLE 3 Modulus at Die C Tear Sample Tensile Failure 50%, 100%, 200%,300%, Strength Number MI strain, psi strain, percent psi psi psi psi(lb/in) 11 54 8560 557 990.5 1170 1590 2660 674.5 12 40 9415 548 10901290 1765 3025 762.5 13 54 8435 532.5 1006.5 1165 1515 2495 692.5 14 688215 532.5 1060 1215 1615 2645 676.5 15 64 8210 509.5 1045 1215 16002655 693.5 16 80 8575 573.5 1130 1285 1610 2500 739 17 140 5100 496 9701075.5 1265 1740 600.5 18 110 6650 561 916 1016.5 1225 1845 564 control30 9860 523.5 1139.5 1340 1880 3395 722.5

As shown in Table 4, Samples 21-25 were prepared from a 90 A ester-basedregrind and/or a 75 A ester based TPU, both of which were derived fromMDI. A 90 A ester based TPU regrind infused with 4% of 1,4 BDO was addedto the respective materials. The melt index of the regrind was 8-20grams/10 minutes at 190 degrees C./8700 sec. The test was performed on a3.5 inch extruder equipped with a melt pump and a 3-roll stand. Theblends were extruded into sheet that was 0.7 millimeters thick by 3 feetwide.

TABLE 4 Sample Number 21 22 23 24 25 Regrind 0.362 0.347 0.607 0.9960.949 TM-75A Coating 0.543 0.520 0.260 0.001 0.000 resin Blue pigment0.001 0.001 0.001 0.002 0.001 UV stabilizer 0.002 0.002 0.002 0.0000.002 BDO infused 0.091 0.130 0.130 0.000 0.047 regrind BDO 0.360%0.520% 0.520% 0.000% 0.190%

The properties of Samples 21-25 are provided in Table 5. The increasedamount of BDO or BDO infused regrind decreased the Die C tear strengthof the samples.

TABLE 5 Sample Number 21 22 23 24 25 Melt Index 142.6 97.3 82.6 — 36.5(190 C./ 8700 grams) Thick (mm) 0.68~0.70 0.7 0.71 0.74~0.78 0.74Durometer 86 87 86~87 92~93 93 (Shore A) Specific 1.205 1.22 1.19251.216 1.2036 Gravity (g/cc) Tensile 4483.1 5063.5 8306.0 6778.7 7641.4Strength (psi) Elongation (%) 561.1 489.5 598.0 380.0 422.3 300% (psi)1504.5 1973.9 1559.2 4143.4 3537.7 Die C tear 494.9 554.3 504.3 575.8632.1 (lb/in) YI 2.06 1.21 2.43 2.73 2.32

With respect to Samples 26-35, the effect of BDO level on the melt indexof a 90 A TPU regrind was determined. The test was performed on a 3.5inch extruder equipped with a melt pump and a 3-roll stand. The productwas a sheet that was 3 feet wide by 0.7 mm thick. The BDO was addedthrough the extruder screw. As illustrated in Table 6, the melt indexincreased with the level of BDO added.

TABLE 6 Melt Index (grams/10 minutes at Estimated BDO 190 degrees C.Barrel Pressure Sample concentration 8700 grams) (psi) 26 0.38 662080-2140 27 0.46 77 2050-2120 28 0.5 77 2000-2080 29 0.65 80 1840-196030 0.7 82 1730-1810 31 0.74 112 1580 32 ~0.88 136 Reduced screw 33 ~0.9150 Reduced screw 34 ~0.97 200 Reduced screw 35 ~1.11 212 Reduced screw

Additional information on Samples 33 and 34 is provided in Table 7,including the notably increased melt index of the Samples.

TABLE 7 Modulus at Die C tear Sample Tensile Failure 50%, 100%, 200%,300%, Strength Number MI strain, psi strain, percent psi psi psi psi(lb/in) 33 150 7446.5 594.5 1026 1108.5 1318.5 1956 632.5 34 200 6430.5580 805.5 884 1085 1680.5 660

With respect to Samples 36 to 39 in Table 8, the effect of adding BDOeither by using a masterbatch that contained 4% BDO on a 90 A esterbased TPU regrind that was derived from MDI was compared with the effectof adding BDO by injection through the screw. The feed contained 30% ofan ester based TPU derived from MDI with a Shore A hardness of 65 A. Thebalance of the feed was either a 90 A ester based regrind derived fromMDI or a mix of the 4% BDO master batch with the 90 A ester basedregrind derived from MDI. The test was performed on a 3.5 inch extruderequipped with a melt pump and a 3-roll stand. The product was a sheetthat was 3 feet wide by 0.7 millimeters thick. The BDO was added throughthe extruder screw. Similar results were obtained using both methods.

TABLE 8 Sample Number Control 36 37 38 39 Regrind 70% 60% 55% 70% 70%TB65-AM 30% 30% 30% 30% 30% 4% 1,4 BDO 10% 15% infused regrind added BDOadded (%) 0.40%   0.60%   % BDO added by 0.40%   0.60%   Liquid additionBarrel Pressure 3680 3280 3140 3160 3175 (psi) Melt Pump 680 610 490 390340 pressure (psi) Roll speed 7 7 7 7 7 Roll deposits none slight heavyslight heavy haze haze haze haze Melt Index 49 79 78 91 (grams/ 10minutes at 190 degrees C./ 8700 grams) Molecular Weight 120000 8830084000 80700 (Mw) Molecular Weight 2.22 2.04 2 1.99 per Number AverageMolecular Weight (Mw/Mn) Melt Index 51 96 104 136 (190 C./ 8700 grams)

Samples 40 to 45 were prepared according to Table 9 to examine theeffect of using different types of glycols. The feed included anester-based TPU derived from MDI that had a Shore A hardness of 65 A, avirgin ester-based TPU derived from MDI, and a 90 A ester-based regrindderived from MDI. The starting mixture had a melt index between 8 and 20grams/10 minutes at 190 degrees C./8700 grams. The glycols were addedthrough the screw. Tripropylene glycol (TPG) and 1,4 cyclohexanedimenthanol (CHDM) produced fewer roll deposits and fumes than glycerinor BDO.

TABLE 9 hardness Shore A 40 41 42 43 44 45 Virgin 90 A TPU 90 A   10%  10%   10%   10%   10%   10% 90 A TPU regrind 90 A   60%   60%   60%  60%   60%   60% TPU 65 A   30%   30%   30%   30%   30%   30% (Coatingcompany TB-65AL ) UV stabilizer 0.25% 0.25% 0.25% 0.25% 0.25% 0.25% Bluepigment 0.15% 0.15% 0.15% 0.15% 0.15% 0.15% Extender None 1,4 BDOGlycerin TPG TPG CHDM Extender level 0.60% 0.40% 1.30% 0.60% 0.96%Barrel Pressure (psi) 2550 1790 1840 1400 1600 Melt Pump pressure 620500 530 380 580 (psi) Screw (RPM) 19.5 19.3 19.0 18.8 18.8 Sheetthickness (mm) 0.7 0.7 0.7 0.7 0.7 0.7 Melt Index 25 145 200 390 122 124(grams/10 minutes at 190 degrees C./8700 grams) Roll fog none some a lotlow low low

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the invention. Individual elements or features ofa particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the invention, and all such modificationsare intended to be included within the scope of the invention.

What is claimed is:
 1. An article of footwear or a component of an article of footwear having a surface element, prepared by a method comprising: providing scrap polyurethane, wherein the scrap polyurethane has a first melt index and a first tearability; mixing the scrap polyurethane with a glycol or polyol additive; increasing the first melt index; forming a sheet from the polyurethane and glycol or polyol additive mixture; applying an area of the sheet to an outer region of an article of footwear or a component of an article of footwear; and forming the surface element, wherein forming the surface element comprises tearing away a perimeter of the sheet around the area.
 2. An article of footwear or a component of an article of footwear having a surface element according to claim 1, wherein increasing the first melt index comprises increasing the melt index of the scrap polyurethane by at least three-fold.
 3. An article of footwear or a component of an article of footwear having a surface element according to claim 1, wherein the scrap polyurethane and glycol or polyol additive are melted together.
 4. An article of footwear or a component of an article of footwear having a surface element according to claim 1, wherein applying the area of the sheet comprises laminating the area of the sheet onto the footwear or the component of an article of footwear.
 5. An article of footwear or a component of an article of footwear having a surface element according to claim 1, wherein additives are added to the scrap polyurethane or to the mixture of the scrap polyurethane with the glycol or polyol additive such that the surface element has an appearance selected from the group consisting of matte appearance and shiny appearance.
 6. An article of footwear or a component of an article of footwear having a surface element according to claim 1, wherein the scrap polyurethane comprises scrap polyurethane from a shoe component.
 7. An article of footwear or a component of an article of footwear having a surface element according to claim 1, wherein forming the surface element comprises tearing away a perimeter of the sheet around the area.
 8. An article of footwear or a component of an article of footwear having a surface element according to claim 7, further comprising applying the perimeter of the sheet to a region of the article of footwear to form a second surface element.
 9. An article of footwear or a component of an article of footwear having a surface element according to claim 1, wherein the surface element has a melt index of at least 100 grams/10 minutes at 190 C/8700 grams as provided by ASTM D1238.
 10. An article of footwear or a component of an article of footwear having a surface element according to claim 1, wherein the glycol or polyol additive comprises butanediol.
 11. An article of footwear or a component of an article of footwear having a surface element according to claim 1, wherein the surface element comprises less than about 5% of the glycol or polyol additive by weight.
 12. An article of apparel or sports equipment with a surface element prepared by a method comprising: providing recycled polyurethane, wherein the recycled polyurethane has a first melt index and a first tearability; mixing the recycled polyurethane with a glycol or polyol additive; increasing the first melt index; forming a sheet from the polyurethane and glycol or polyol additive mixture; applying an area of the sheet to an outer region of an article of apparel or sports equipment; and forming the surface element, wherein forming the surface element comprises tearing away a perimeter of the sheet around the area.
 13. An article of apparel or sports equipment with a surface element according to claim 12, wherein increasing the first melt index comprises increasing the melt index of the recycled polyurethane by at least three-fold.
 14. An article of apparel or sports equipment with a surface element according to claim 12, wherein applying the area of the sheet comprises laminating the area of the sheet onto the article of apparel or sports equipment.
 15. An article of apparel or sports equipment with a surface element according to claim 12, wherein additives are added to the recycled polyurethane or to the mixture of the recycled polyurethane with the glycol or polyol additive, such that the surface element has an appearance selected from the group consisting of matte appearance and shiny appearance.
 16. An article of apparel or sports equipment with a surface element according to claim 12, wherein the recycled polyurethane comprises scrap polyurethane from a shoe component.
 17. An article of apparel or sports equipment with a surface element according to claim 12, wherein forming the surface element comprises tearing away a perimeter of the sheet around the area.
 18. An article of apparel or sports equipment with a surface element according to claim 12, wherein the surface element has a melt index of at least 100 grams/10 minutes at 190 C/8700 grams as provided by ASTM D1238.
 19. An article of apparel or sports equipment with a surface element according to claim 12, wherein the glycol or polyol additive comprises butanediol.
 20. An article of apparel or sports equipment with a surface element according to claim 12, wherein the surface element comprises less than about 5% of the glycol or polyol additive by weight. 